Staff Controls Engineer, System Manager (GDE Assembly)

Are you ready to build America’s energy future? Form Energy is an American manufacturing and energy technology company. We’re revolutionizing energy storage with cost-effective, multi-day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. By strengthening the electric system and reimagining what’s possible, we’re giving clean energy a whole new form! 

In recent years, Form Energy has earned a number of accolades, including being named by TIME as a “Best Invention”, MIT Technology Review as a “Top Climate Tech Company To Watch”, and Fast Company as “One of the Next Big Things In Tech”. We are making rapid progress on our mission of delivering energy storage for a better world, and our team is growing just as rapidly to meet demand. We have signed contracts with leading electric utilities across the United States and production of our iron-air batteries is underway at our first high-volume manufacturing facility in West Virginia.

Working for Form Energy is more than just a job, it’s a chance to be part of something extraordinary. And now - right as we significantly scale up battery manufacturing -  might be the most exciting moment in the company’s history to join. We are assembling a team of highly talented and driven individuals across the country. Driven by our core values of humanity, excellence, and creativity, our team is determined to deliver on our mission and transform the energy landscape for the better.

Feeling energized to make a meaningful impact on the world? Then keep reading - you’ve come to the right place.

Role Description

We are looking for a staff level controls engineer to join the Manufacturing Control and Execution Systems - System Manager team. In this role you will be responsible for design, development, and deployment of novel equipment used to manufacture Form Energy’s Iron-Air battery. This role offers an exciting opportunity to be part of a mission critical team that owns control and execution systems throughout their lifecycle including design, development, deployment, and sustaining.

Reporting to our Senior Staff Controls Engineer, System Managers, you will be part of a quickly-growing manufacturing control and execution systems team. In this leadership role, you will be overseeing multiple controls projects and teams, assuring that control systems meet the high standards of functionality, quality, and reliability that is needed for production. You will own all deliverables for control systems within your assigned area, so attention to detail and ability to effectively lead engineering efforts are critical in this role. You will manage all phases of the control system lifecycle including design, development, deployment, and sustaining. You will have the opportunity to lead multiple large control and execution system projects while mentoring other engineers both technically and professionally.

Bringing your extensive experience in control system design, development, and deployment; you will work closely with a variety of teams, both technical and operational, at Form Factory 1. You will be the primary contact for process and mechanical engineers as well as operations for controls deliverables which include PLC, SCADA, Robotics, Electrical, Instrumentation, Robotics, Vision, and MES.

This opportunity is based out of Form Factory 1 – Form Energy’s 550,000-square-foot, state-of-the-art manufacturing facility located in Weirton, WV, a commutable distance from Pittsburgh. Purpose-built for high-volume, advanced battery production, Form Factory 1 is a hub of fast-moving, collaborative work driving a new era of large-scale American energy manufacturing in the heart of the Rust Belt.

Relocation assistance is available.

What you'll do:

• Responsible for design, development, deployment, and sustaining of industrial control and execution systems

• Serve as the owner of all systems and projects for an assigned area, directing the efforts of controls engineers for Automation, Robotics & Vision, Electrical & Instrumentation, and SCADA to assure all technical requirements are met on budget and on schedule

• Provide technical guidance and mentorship to less experienced controls engineers

• Work with the sustaining team to assure all technicians have been trained to support the control systems within your assigned area

• After escalation from our sustaining team, provide controls support for the production operations and maintenance departments, coordinating efforts of the controls team to troubleshoot as required to reduce equipment and process downtime, provide throughput improvement, and/or address any safety concerns

• Own the rotating on-call schedule with responsibilities for off-hour escalations from our sustaining team

• Work directly with equipment vendors and internal technical leads to assure they are following Form Energy Equipment Standards to deliver quality control systems, including executing FATs at vendor sites and SATs at Form Factory 1

• Execution of internal projects, including determining resources needed to successfully execute, direct ownership of all deliverables to our end customers, and assuring solutions are reliable for production use

• Utilize input from production, maintenance supervisors, operators, vendors, and service providers to provide direction to controls teams as well as troubleshooting assistance to make improvements

• Responsible for following and assuring team members comply with all Safety and Environmental policies and procedures

What you'll bring:

• PLC Programming and Troubleshooting

  • Siemens TIA-Portal (Required, execute independently)

  • Rockwell Studio 5000 (Required, execute independently)

  • Beckhoff TwinCat (Nice to Have)

• SCADA/HMI Systems

  • Ignition Perspective (Required, execute independently)

  • Siemens WinCC (Required, with supervision)

  • Rockwell FTView ME (Required, with supervision)

  • IPC and Panel PC setup and deployment (Required, with supervision)

• Robotics

  • FANUC (Required, with supervision)

  • FANUC ROBOGUIDE (Required, basic knowledge)

  • Epson (Nice to Have)

  • Kawasaki (Nice to Have)

• Vision

  • Keyence and Cognex Barcode Scanner (Required, execute independently)

  • Keyence and Cognex Inspection (Required, with supervision)

  • Position (Required, basic knowledge)

• MES

  • PLC Product Tracking Programming (Required, can train others)

  • PLC Handshake/Data Programming (Required, can train others)

  • Ignition Integration for Data (Required, execute independently)

  • Quickbase (Nice to Have)

• Electrical

  • AutoCAD Electrical Design (Nice to Have)

  • SolidWorks Design (Nice to Have)

  • Review/Redline/Read Electrical Schematics (Required, can train others)

  • Troubleshoot (Required, can train others)

• OT Network

  • Configure Siemens Scalance Managed Network Switches (Nice to Have)

  • Troubleshoot (Required, execute independently)

• Functional Safety (ProfiSafe, CIP Safety, Hardwired)

  • Electrical and Hardware selection and design (Nice to Have)

  • Siemens ProfiSafe and Safety Programming (Required, execute independently)

  • Rockwell CIP Safety and Safety Programming (Required, execute independently)

  • FANUC DCS Programming (Required, execute independently)

• Review Electrical, Hardware, and Programming (Required, execute independently)

• Troubleshoot (Required, execute independently)

• iba (Required, execute independently)

• Octoplant (Required, execute independently)

• Problem-solving

  • Read and interpret schematics, diagrams, and blueprints to troubleshoot and repair controls components (Required)

  • Attention to detail when testing and troubleshooting (Required)

• Recording data and documenting procedures (Required)

• Bachelor Degree in Electrical/Controls/Mechatronics or equivalent experience

• Extensive controls experience in a Manufacturing Environment

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Humanity is a cornerstone of Form Energy’s culture, and we make sure our compensation and benefits reflect that. Form Energy offers competitive salaries, stock options, and a holistic benefits package to ensure all employees have what they need to thrive while working here. 

When it comes to you and your family’s health, we cover 100% of medical, dental, and vision premiums for full-time employees - and 80% of healthcare premiums for dependents. This starts from day one. We also offer at least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents), and generous vacation policies to give employees time to recharge when needed. 

To build America’s energy future, we need everyone at the table. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs.

If you may require reasonable accommodations to participate in our interview process, please contact [email protected]. Requests for accommodations will be treated with discretion.

Form Energy is committed to maintaining the privacy of our applicants. Please be aware that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.